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dsPIC33EP32MC204

MICROCHIP dsPIC33EP32MC204 User guide

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dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide
2023 Microchip Technology Inc Page 0
dsPIC33EP32MC204 - Drone
Propeller Reference Design
User’s Guide
dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide
Table of Contents
Chapter 1 Introduction ............................................................................................. 0
1.1 OVERVIEW ..................................................................................................................................... 0
1.2 FEATURES ...................................................................................................................................... 1
1.3 BLOCK DIAGRAM ........................................................................................................................... 2
Chapter 2 Board Interface Description ................................................................... 4
2.1 INTRODUCTION ............................................................................................................................. 4
2.2 BOARD CONNECTORS ................................................................................................................... 4
2.3 USER INTERFACE ........................................................................................................................... 7
Chapter 3 Hardware Description ........................................................................... 11
3.1 INTRODUCTION ........................................................................................................................... 11
3.2 Hardware sections ...................................................................................................................... 11
3.3 Hardware connections ................................................................................................................ 12
Appendix A Schematics ..................................................................................... 17
A.1 BOARD SCHEMATICS .................................................................................................................. 17
Appendix B Electrical Specifications ................................................................... 20
B.1 INTRODUCTION ........................................................................................................................... 20
Appendix C Bill of Materials (BOM) .................................................................... 21
C.1 BILL OF MATERIALS: .................................................................................................................... 21
Appendix D Test Results ....................................................................................... 23
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Chapter 1 Introduction
1.1 OVERVIEW
The reference design is a low-cost evaluation platform targeted for quad copter/drone applications
with propellers driven by three-phase Permanent Magnet Synchronous or Brushless motors. This
design is based on a Microchip dsPIC33EP32MC204 DSC, a motor control device.
dsPIC33EP32MC204 - Drone Propeller Reference Design User's Guide
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FIGURE 1-1: dsPIC33EP32MC204 Drone motor controller reference design
1.2 FEATURES
Key features of the Reference Design are as follows:
• Three-Phase Motor Control Power Stage
• Phase current feedback via two shunt method for higher performance
• Phase voltage feedback to implement sensor-less trapezoidal control or flying start
• DC Bus voltage feedback for over-voltage protection
• ICSP header for In-Circuit Serial Programming using Microchip Programmer/Debugger
• CAN Communication Header
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1.3 BLOCK DIAGRAM
FIGURE 1-2: Block Diagram – Reference Design
Three Phase Inverter
Program/
Debug
Interface
User
Interface
CAN
Communication
Interface
Header P5
Gate Driver
MCP8026
+3.3V
+12V
Terminals
10-16 VDC
MCU Reset
ICSP
Header ISP1
Three Phase
Inverter Bridge
Shunt
Bus Current
Sensing
To
Motor
Reset
Control
IO Control – Analog, Digital, Pull-Up, Pull-Down, Remappable, Change Notification
ICSP
Program
/Debug
PWM
UART
CTMU
ADC –
Shared
Core
QEI
Timer 1
CPU
Input
Capture and
Output
Compare
Clock
SPI
I2C
ECAN1
DMT
CLC
CRC
Op Amps &
Comparators
WDT
PTG
Interrupt
Control
DMA
PWMxH/ PWMxL
Signals
Current Shunt
Feedback
Phase
Voltages
Scaling
Circuit
Phase
Voltages
PHA,
PHB
PHC
DC
Voltage
Scaling
Circuit
Input Filter
Terminals
dsPIC DSC – dsPIC33EP32MC204
Speed
reference
PWM and
analog input
Header P2
Serial UART
Interface
Header P3
3.3V filter
and
feedback
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The various hardware sections of the Reference Design are shown in Figure 1-3 and summarized in
Table 1-1.
FIGURE 1-3: HARDWARE SECTIONS
Table 1-1 Hardware Sections
Section
Hardware Section
1
Three-phase motor control inverter
2
dsPIC33EP32MC204 and associated circuit
3
MCP8026 MOSFET Driver
4
CAN Interface
5
Current Sensing Resistors
6
Serial Communication Interface Header
7
ICSP™ Header
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Chapter 2 Board Interface Description
2.1 INTRODUCTION
This chapter provides a more detailed description of the input and output interfaces of the Drone motor
controller Reference Design. The following topics are covered:
• Board Connectors
• Pin functions of the dsPIC DSC
• Pin functions of the MOSFET Driver
2.2 BOARD CONNECTORS
This section summarizes the connectors in the Smart Drone Controller Board. They are shown in
Figure 2-1 and summarized in Table 2-1.
• Supplying input power to the Smart Drone Controller Board.
• Delivering inverter outputs to the motor.
• Enabling the user to program/debug the dsPIC33EP32MC204 device.
• Interfacing to CAN network.
• Establishing serial communication with the host PC.
• Supplying the speed reference signal.
FIGURE 2-1: CONNECTORS – Drone Motor Controller Reference Design
8
User Interface Header
9
DE2 MOSFET Driver Serial Interface Header
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2.2.1 ICSP™ Header for Programmer/Debugger Interface (ISP1)
The 6-pin header ISP1 can connect with the programmer, for example, PICkit 4, for programming and
debugging purposes. This is not come populated. Populate when needed with Part Number 68016-
106HLF or similar. The pin details are provided in Table 2-2.
TABLE 2-2: PIN DESCRIPTION – HEADER ISP1
Pin #
Signal Name
Pin Description
1
MCLR
Device Master Clear (MCLR)
2
+3.3V
Supply voltage
3
GND
Ground
4
PGD
Device Programming Data Line (PGD)
5
PGC
Device Programming Clock Line (PGC)
2.2.2 CAN Communication Interface Header(P5)
This 6-pin header can be used for interfacing to CAN network. The pin details are provided in Table 2-
3.
TABLE 2-3: PIN DESCRIPTION - HEADER P5
Pin #
Signal Name
Pin Description
1
3.3 V
Supplies 3.3 volts to an external module (10 ma. Max)
2
STANDBY
Input Signal to place smart controller in standby
3
GND
Ground
4
CANTX
CAN transmitter (3.3 V)
5
CANRX
CAN receiver (3.3 V)
6
DGND
Connected to the digital ground on the board
TABLE 2-1 CONNECTORS
Connector
Designator
No of
Pins
Status
Description
ISP1
5
Populated
ICSP™ Header – Interfacing Programmer/Debugger to the
dsPIC® DSC
P5
6
Populated
CAN Communication Interface Header
P3
2
Populated
Serial Communication Interface Header
P2
2
Populated
Reference Speed PWM/Analog Interface Header
PHASE A,
PHASE B,
PHASE C
3
Not
Populated
Three-Phase inverter outputs
VDC, GND
2
Not
Populated
Input DC supply tab connector
(VDC: Positive terminal, GND: Negative terminal)
P1
2
Populated
DE2 MOSFET Driver Serial Interface Header. Please refer to
MCP8025A/6 data sheet for hardware and communication
protocol specifications
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2.2.3 Speed Reference UI Header (P2)
The 2-pin Header P2 is used for providing a Speed reference to the firmware via 2 methods. The pins
are short circuit protected. Details of the header P2 are given in Table 2-4.
TABLE 2-4: PIN DESCRIPTION - HEADER P2
Pin #
Signal Name
Pin Description
1
INPUT_FMU_PWM
Digital signal – PWM 50Hz, 3-5Volts, 4-85%
2
AD SPEED
Analog signal – 0 to 3.3 V
2.2.4 Serial Communications Header (P3)
The 2-pin Header P3 can be used for accessing unused pins of the microcontroller for function
expansion or debugging, and the pin details of the header J3 are given in Table 2-4.
TABLE 2-4: PIN DESCRIPTION - HEADER P3
Pin #
Signal Name
Pin Description
1
RXL
UART - Receiver
2
TXL
UART - Transmitter
2.2.5 DE2 MOSFET Driver Serial Interface Header (P1)
The 2-pin Header P1 can be used for accessing unused pins of the microcontroller for function
expansion or debugging, and the pin details of the header J3 are given in Table 2-4.
TABLE 2-4: PIN DESCRIPTION - HEADER P1
Pin #
Signal Name
Pin Description
1
DE2
UART – DE2 Signal
2
GND
Board Ground used for external connection
2.2.6 Inverter Output Connector
The reference design can drive a three-phase PMSM/BLDC motor. Pin assignments of the connector
are shown in Table 2-6. The correct phase sequence of the motor must be connected to prevent
reverse rotation.
TABLE 2-6: PIN DESCRIPTION
Pin #
Pin Description
PHASE A
Phase 1 output of inverter
PHASE B
Phase 2 output of inverter
PHASE C
Phase 3 output of inverter
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2.2.7 Input DC Connector (VDC and GND)
The board is designed to operate in the DC voltage range of 11V to 14V, which can be powered through
connectors VDC and GND. The connector details are given in Table 2-7.
TABLE 2-7: PIN DESCRIPTION
Pin #
Pin Description
VDC
DC Input supply positive
GND
DC Input supply negative
2.3 USER INTERFACE
There are two ways to interface to the Smart Drone Controller firmware to provide a speed reference input.
• PWM input (Digital signal - PWM 50Hz, 3-5Volts, 4-55% Duty cycle)
• Analog voltage (0 – 3.3 Volts)
The interface is done via connections to the P2 connector. See Table 2-4 for details.
This reference design has an external accessory PWM controller module that provides the speed
reference. The external controller has its own potentiometer and 7 segment LED display. The
potentiometer can be used to adjust the desired speed by changing the PWM duty cycle that can be
varied from 4% to 55%. (50Hz 4-6Volts) in 3 ranges.
See Section 3.3 for more information.
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2.4 PIN FUNCTIONS OF THE dsPIC DSC
The onboard dsPIC33EP32MC204 device controls the reference design's various features through its
peripherals and CPU capability. Pin functions of the dsPIC DSC are grouped according to their
functionality and presented in Table 2-9.
TABLE 2-9: dsPIC33EP32MC204 PIN FUNCTIONS
Signal
dsPIC DSC
Pin
Number
dsPIC DSC
Pin Function
dsPIC DSC Peripheral
Remarks
dsPIC DSC Configuration – Supply, Reset, Clock, and Programming
V33
28,40
VDD
Supply
+3.3V Digital supply to dsPIC DSC
DGND
6,29,39
VSS
Digital Ground
AV33
17
AVDD
+3.3V Analog supply to dsPIC DSC
AGND
16
AVSS
Analog Ground
OSCI
30
OSCI/CLKI/RA2
External oscillator
No external connection.
RST
18
MCLR
Reset
Connects to ICSP Header (ISP1)
ISPDATA
41
PGED2/ASDA2/RP37/RB5
In-Circuit Serial
Programming
(ICSP™) or
In-circuit debugger
Connects to ICSP Header (ISP1)
ISPCLK
42
PGEC2/ASCL2/RP38/RB6
IBUS
18
DACOUT/AN3/CMP1C/RA3
High Speed Analog
Comparator 1(CMP1) and
DAC1
Amplified Bus current is further filtered
before connecting to the positive input
of CMP1 for over-current detection. The
over-current threshold is set through
DAC1. The comparator output is
internally available as fault input of the
PWM generators to shut down PWMs
without CPU intervention.
Voltage Feedback
ADBUS
23
PGEC1/AN4/C1IN1+/RPI34/R
B2
Shared ADC Core
DC Bus voltage feedback.
Debug Interface (P3)
RXL
2
RP54/RC6
Remappable Function of
I/O and UART
These signals are connected to Header
P3 to interface UART serial
communication.
TXL
1
TMS/ASDA1/RP41/RB9
CAN Interface (P5)
CANTX
3
RP55/RC7
CAN receiver, transmitter
and standby
These signals are connected to Header
P5
CANRX
4
RP56/RC8
STANDBY
5
RP57/RC9
PWM Outputs
PWM3H
8
RP42/PWM3H/RB10
PWM Module output.
Refer to the datasheet for more details.
PWM3L
9
RP43/PWM3L/RB11
PWM2H
10
RPI144/PWM2H/RB12
PWM2L
11
RPI45/PWM2L/CTPLS/RB13
PWM1H
14
RPI46/PWM1H/T3CK/RB14
PWM1L
15
RPI47/PWM1L/T5CK/RB15
General purpose I/O
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I_OUT2
22
PGEC3/VREF+/AN3/RPI33/CT
ED1/RB1
Shared ADC Core
MotorGateDr_
CE
31
OSC2/CLKO/RA3
I/O Port
Enables or disables the MOSFET
driver.
MotorGateDrv
_ILIMIT_OUT
36
SCK1/RP151/RC3
I/O Port
Overcurrent protection.
DE2
33
FLT32/SCL2/RP36/RB4
UART1
Reprogrammable port configured to
UART1 TX
DE2 RX1
32
SDA2/RPI24/RA8
UART1
Reprogrammable port configured to
UART1 RX
Scaled Phase voltage measurement
PHC
21
PGED3/VREF-/
AN2/RPI132/CTED2/RB0
Shared ADC Core
Back emf zero cross sensing PHASE C
PHB
20
AN1/C1IN1+/RA1
Shared ADC Core
Back emf zero cross sensing PHASE B
PHA,
Feedback
19
AN0/OA2OUT/RA0
Shared ADC Core
Back emf zero cross sensing PHASE A
No connections
-
35,12,37,38
-
43,44,24
-
30,13,27
2.5 PIN FUNCTIONS OF THE MOSFET DRIVER
Signal
MCP8026
Pin
Number
MCP8026
Pin Function
MCP8026 Function
block
Remarks
Power and Ground connections
VCC_LI_PO
WER
38,39
VDD
Bias generator
11-14 Volts
PGND
36,35,24,20
,19,7
PGND
Power ground
V12
34
+12V
12 Volt output
V5
41
+5V
5 Volt output
LX
37
LX
Buck regulator switch node for 3.3V out
FB
40
FB
Buck regulator feedback node for 3.3V
out
PWM output
PWM3H
46
PWM3H
Gate control logic
Refer to device datasheet for more
details
PWM3L
45
PWM3L
PWM2H
48
PWM2H
PWM2L
47
PWM2L
PWM1H
2
PWM1H
PWM1L
1
PWM1L
Current sensing pins
I_SENSE2-
13
I_SENSE2-
Motor Control Unit
Phase A shunt -ve
I_SENSE2+
14
I_SENSE2+
Phase A shunt +ve
I_SENSE3-
10
I_SENSE3-
Phase B shunt -ve. Note this shunt is
on W half bridge of the inverter.
I_SENSE3+
11
I_SENSE3+
Phase B shunt +ve. Note this shunt is
on W half bridge of the inverter.
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I_SENSE1-
17
I_SENSE1-
Motor Control Unit
Reference voltage -ve
I_SENSE1+
18
I_SENSE1+
3.3V/2 reference voltage +ve
I_OUT1
16
I_OUT1
Buffered output 3.3V/2 Volts
I_OUT2
12
I_OUT2
Amplified output Phase A current
I_OUT3
9
I_OUT3
Amplified output Phase B current
Serial DE2 Interface
DE2
44
DE2
Bias generator
Serial interface for driver configuration
MOSFET gate inputs
U_Motor
30
PHA
Gate control logic
Connects to the Motor phases.
V_Motor
29
PHB
W_Motor
28
PHC
High Side MOSFET gate drive
HS0
27
HSA
Gate control logic
High side MOSFET Phase A
HS1
26
HSB
High side MOSFET Phase B
HS2
25
HSC
High side MOSFET Phase C
Bootstrap
VBA
33
VBA
Gate control logic
Boot Strap capacitor output Phase A
VBB
32
VBB
Boot Strap capacitor output Phase B
VBC
31
VBC
Boot Strap capacitor output Phase C
Low Side MOSFET gate drive
LS0
21
LSA
Gate control logic
Low side MOSFET Phase A
LS1
22
LSB
Low side MOSFET Phase B
LS2
23
LSC
Low side MOSFET Phase C
Digital I/O
MotorGateDrv
_CE
3
CE
Communication port
Enables the MC8026 MOSFET driver.
MotorGateDrv
_ILIMIT_OUT
15
ILIMIT_OUT ( Active low)
Motor Control Unit
No connects
-
8
LV_OUT1
-
4
LV_OUT2
-
6
HV_IN1
-
5
HV_IN2
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Chapter 3 Hardware Description
3.1 INTRODUCTION
The Drone Propeller Reference Design Board is intended to demonstrate the capability of the small pin
count motor control devices in the dsPIC33EP family of single core Digital Signal Controllers (DSCs).
The control board incorporates bare minimal componentry to reduce weight. The PCB area could be
further shrunk in size for the production intent version. The board can be programmed via the In System
Serial Programming connector and incorporates two current sense resistors and a MOSFET driver. A
CAN interface connector is provided for communication with other controllers and to provide reference
speed information if needed.
The controller’s inverter takes an input voltage in the range of 10V to 14V and can deliver a continuous
output phase current of 8A (RMS) in the specified operating voltage range. For more information on
electrical specifications, see Appendix B. “Electrical Specifications”.
3.2 HARDWARE SECTIONS
This chapter covers the following hardware sections of the Drone Propeller Reference Design Board:
• dsPIC33EP32MC204 and associated circuitry
• Power Supply
• Current Sense Circuitry
• MOSFET gate driver circuitry
• Three-Phase Inverter Bridge
• ICSP Header/Debugger Interface
3.2.1 dsPIC33EP32MC204 and associated circuitry
3.2.2 Power Supply
The controller board has three regulated voltage outputs 12V, 5V and a 3.3V generated by the
MCP8026 MOSFET driver.
The 3.3 volts is generated using the MCP8026 onboard buck regulator and a feedback
arrangement. See red box in FIGURE A-1 in the schematics section.
The external power supply from the battery is directly applied to the inverter via the power
connectors. A 15uF capacitor provides the DC filtering for stable operation during rapid load changes.
Please see device (MCP8026) data sheet for output current capability of each voltage output.
3.2.3 Current Sense Circuitry
Current is sensed using the popular “two shunt” approach. Two 10 milliohm shunts provide the
current input to the inputs of the on-chip Op-Amps. The Op-Amps are in differential gain mode with a
gain of 7.5 providing a 22Amp peak phase current measurement capability. The amplified current signal
from phase A (U half-bridge) and Phase B (W half-bridge) is converted by the dsPIC controller firmware.
A voltage reference with a buffered output for 3.3V / 2 provides for noise free zero reference for
the current sense circuits.
See Schematics section FIGURE A-4 for details.
3.2.4 MOSFET gate driver circuitry
The gate drive is handled internally except for the bootstrap capacitors and diodes which are
located on the board and designed keeping in mind to adequately turn ON the MOSFETs at the lowest
operating voltage. See specifications for MCP8026 operating voltage range in the data sheet.
See Schematics section FIGURE A-1 for interconnect details.
3.2.5 Three- Phase Inverter Bridge
The inverter is the standard 3 Half bridges with 6 N Channel MOSFET devices capable of
operation in all the 4 quadrants. The MOSFET driver directly interfaces through the slew rate limiting
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series resistors to the Gates of the MOSFETs. A standard boot strap circuit comprising of a network of
capacitors and diodes is provided for each of the high side MOSFETs for adequate turn ON gate voltage.
The bootstrap capacitors and diodes are rated for full operating voltage range and current.
The output of the three-phase inverter bridge is available on U, V and W for the three phases of
the motor.
See Schematics section FIGURE A-4 for connectivity and other details.
3.2.6 ICSP Header/Debugger Interface
Programming the Smart Drone Controller board:
Programming and debugging are via the same ICSP connector ISP1. Use the PICKIT 4 to
program with the PKOB connector, connected 1 to 1 as given in table 2-2. You can program either with
the MPLAB-X IDE or MPLAB-X IPE. Power up the board with 11-14 Volts. Select the appropriate hex
file and follow instructions on the IDE/IPE. Programming is complete when a “Programming/Verifying
complete” message is displayed in the output window.
Refer to MPLAB PICKIT 4 data sheets for debugging instructions.
3.3 HARDWARE CONNECTIONS
This section describes a method to demonstrate the operation of the Drone controller. The reference
design requires a few extra off-board accessory modules and a motor.
• A 5V power supply to the PWM controller
• PWM controller used to supply a speed reference or a potentiometer to supply a varying voltage
speed reference
• A BLDC motor with parameters as described in Appendix B
• A battery power source of 11-14V and 1500mAH capacity
Any compatible make or model can be used to replace the ones shown here for successful operation.
Shown below are examples of the above accessories and motor used for this demonstration.
5V switching regulator:
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PWM Controller:
BLDC motor: DJI 2312
Battery:
Operating instructions:
Follow the steps as below:
Note: DO NOT ATTACH THE PROPELLER AT THIS TIME
Step 1: Main power source connection
Connect the battery ‘+’ and ‘-‘ to the VDC and GND terminals to power the smart controller.
A DC power supply can also be used.
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Step 2: Speed reference signal to the smart Drone controller.
The controller takes speed input reference from the PWM controller at 5V max peak. The output
of the PWM controller provides a ground referenced 5V signal output that connects to a 5V tolerant input
pin as shown in the picture. Also shown is the location for the ground connection.
Step 3: Power supply to the PWM controller.
Connect the Switching regular input to the battery terminals and the output (5V) to the PWM
controller supply.
Step 4: PWM controller configuration:
The signal pulse width is from the PWM controller is validated for a valid signal in firmware to
prevent spurious turn ON and over speeding.
The controller has two push button switches. Select the manual mode of operation using the
“Select” switch.
Use the “Pulse Width” button to select between 3 levels of speed control. The switch cycles
through 3 ranges for PWM duty cycle output with each press.
Range 1: 4-11%
Range 2: 10-27.5%
Range 3: 20-55%
The display indication varies from 800 to 2200 for a linear change in duty cycle within the range.
Turning the potentiometer on the PWM controller will increase or decrease the PWM output.
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Step 5: Motor terminal connection:
Connect the motor terminals to PHASE A,B and C. The sequence decides the direction of
rotation of the motor. The desired rotation of the Drone is clockwise looking into the motor to prevent the
propellar from loosening. It is therefore important to confirm the rotation direction before mounting the
blades.
Supply a PWM reference signal by tweaking the potentiometer on the PWM controller starting
with the least pulse width position (800). The motor will start spinning at 7.87% duty cycle (50Hz) and
above. The 7-Segment display shows 1573 (7.87% duty cycle) to 1931 (10.8% duty cycle) when the
motor spins. Confirm the direction of rotation is counterclockwise. If not swap any two connections to the
motor terminals.
Return the potentiometer to the lowest speed setting.
Step 6: Mounting the Propeller:
Disconnect battery power. Mount the propeller blade by screwing it into the motor shaft in the
clockwise direction. Hold the stick/motor firmly with arm stretched out and at a safe distance from all
obstacles and people while in operation. Connect the power supply. The propeller action will exert force
against the hand when spinning, so a firm grip is essential to prevent bodily injury. Tweak the
potentiometer to change the speed (display indicates between 1573 and 1931)
This completes the demonstration.
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The below picture shows the overall wiring setup for the demonstration.
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Appendix A Schematics
A.1 BOARD SCHEMATICS
This section provides schematics diagrams of the dsPIC33EP32MC204 Drone Propeller Reference
Design. The reference design uses a four-layer FR4, 1.6 mm, Plated-Through-Hole (PTH) construction.
Table A-1 summarizes the schematics of the Reference Design:
TABLE A-1: SCHEMATICS
Figure
Index
Schematics
Sheet No.
Hardware Sections
Figure A-1
1 of 4
dsPIC33EP32MC204-dsPIC DSC(U1) Interconnections
MCP8026-MOSFET driver interconnections
3.3V analog and digital filter and feedback network
dsPIC DSC internal operational amplifiers for amplifying Bus Current
Bootstrap network.
Figure A-2
2 of 4
In-System Serial Programming Header ISP1
CAN Communication Interface Header P5
External PWM speed control Interface Header P2
Serial Debugger Interface P3
Figure A-3
3 of 4
DC Bus voltage scaling resistor divider
Back-emf voltage scaling network
Op-Amp gain and reference circuitry for phase current sensing
Figure A-4
4 of 4
Motor Control Inverter –Three-phase MOSFET bridge
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